Stephen Fitz-Gerald

Hey Bobby,
Yeah, you gotta walk before you can run.
I worked in a trailer factory for 6 years and took 5% of every paycheck to buy tools and start my own studio...
As regards this particular rail,It was definitely made in bolt together sections. That's the only way I could handle it by my self in my small shop without a lift etc.I think the flatbar frame for each section was 1/2 inch by 1 1/2. I like using 1/2 inch material for railing frames because it stays rigid so well, especially when I'm welding many pieces INSIDE the frame at odd intervals (which would usually cause irregular heat warping)... The irregular and organic shapes WITHIN the top and bottom rails are done in 1/4 x 1 flatbar.

OOPS;
I just looked at the picture and realized that for this stairway section,I had purchased a STOCK cap rail(hand rail)and cut and forged it to my purpose. the rest of the interior rails of the house are 2"x1/2"(I think).

Don't feel bad Will.
There are so many factors,angles,pitch,role etc. with a spiral stair rail like this,it requires many trial fits and returns.Basically I tack weld the frame as I think it ought to be from my measurements,take it to the site,see what needs to be adjusted and keep going back and forth refining it until it fits just right.
I will say this job was made infinitely easier because the guys that made the stairway before me were consummate professionals and perfectionists.Every stair was EXACTLY the same height. They also gave me a scale schematic of the stairway with several views.This helped immeasurably to ascertain the overall radius.
For the hand rail on the outside of the stairway we opted for some help from a company that has a big roller machine and comes on site to role the hand rail.It was one piece 45 feet long,but they did a great job. I then took it back to my studio to weld on all the brackets and scroll ends...

Stephen Fitz-Gerald
Dear Will,
You're not alone.
A job like this from the outset can be somewhat overwhelming and requires many many measurements,but the key for me has been to conceptualize the whole composition first so that it can be conveyed to the client in a fairly good sketch,and then break it up into easily digestible parts so-to-speak.Thus you'll notice each section is from 5 to 8 feet long and usually resting on 3 angle blocks which rest on and are bolted to the the edge of the stairway.So I would start with those three blocks ,make sure their angles are correct,and proceed up the stairway to the next section.Often I will tack weld a piece (such as the verticals)with only one tack at the bottom corner so that I can move the bar around just a little and adjust it's position without braking the tack weld.Then I have to VERY CAREFULLY get it back to my studio and weld it solid.So there are lots of little tricks one can use to accomplish such a job.The bottom line is,if you get offered such an opportunity,you HAVE to take it,or you'll kick yourself for the rest of your life for passing it up from fear.I may not actually KNOW at first how I'm going to pull off something like this,but I have every confidence that i will figure it out,do the homework required,or get some good advice from somebody who does.I have a few things going for me. I've been around unusual metal fabrication all my life,so i have a pretty good understanding of what the material can do,and I have nearly photographic memory for angles,I mean I'm a natural at geometry though I do get messed up about left and right sometimes...LOL
For me the bottom line has always been,challenges are how I grow.Taking me outside my comfort zone always makes me stretch my artistic and intellectual muscles,and as long as there's enough money involved I can be VERY patient with the process and VERY methodical with the project...